Method and apparatus for monitoring refrigerant-cycle systems

• US 7,275,377 B2
• Filed: 08/11/2004
• Issued: 10/02/2007
• Est. Priority Date: 08/11/2004
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Lawrence Kates
• Inventors: Kates, Lawrence
• Primary Examiner(s): NORMAN, MARC E
• Application Number:
  US10/916,222
• Publication Number:
  US 20060032245A1
• Time in Patent Office: 1,147 Days
• Field of Search: 621/26, 621/29, 622/08, 622/09, 622/30, 165/11.1, 236/94
• US Class Current: 62/129
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/32 Responding to malfunctions or emergencies
• CPC Class Codes: F24F 11/39 Monitoring filter performance
• CPC Class Codes: F24F 11/47 Responding to energy costs
• CPC Class Codes: F24F 11/56 Remote control
• CPC Class Codes: F24F 8/90 Cleaning of purification apparatus
• CPC Class Codes: F25B 2500/19 Calculation of parameters
• CPC Class Codes: F25B 2600/07 Remote controls
• CPC Class Codes: F25B 2700/02 Humidity
• CPC Class Codes: F25B 2700/133 through the condenser
• CPC Class Codes: F25B 2700/1351 of the cooled fluid upstream or downstream of the evaporator
• CPC Class Codes: F25B 2700/15 Power, e.g. by voltage or current
• CPC Class Codes: F25B 2700/151 of the compressor motor
• CPC Class Codes: F25B 2700/172 of the condenser fan
• CPC Class Codes: F25B 2700/1931 Discharge pressures
• CPC Class Codes: F25B 2700/1933 Suction pressures
• CPC Class Codes: F25B 2700/195 of the condenser
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• CPC Class Codes: F25B 2700/21151 at the suction side of the compressor
• CPC Class Codes: F25B 2700/21152 at the discharge side of the compressor
• CPC Class Codes: F25B 2700/21161 : of the fluid heated by the condenser
• CPC Class Codes: F25B 2700/21163 : of the refrigerant at the outlet of the condenser
• CPC Class Codes: F25B 2700/21172 : at the inlet
• CPC Class Codes: F25B 2700/21173 : at the outlet
• CPC Class Codes: F25B 2700/21174 : of the refrigerant at the inlet of the evaporator
• CPC Class Codes: F25B 2700/21175 : of the refrigerant at the outlet of the evaporator
• CPC Class Codes: F25B 49/00 : Arrangement or mounting of control or safety devices
• CPC Class Codes: F25B 49/005 : of safety devices F25B49/02 and F25B49/04 take precedence
• CPC Class Codes: F25D 2400/36 : Visual displays
• CPC Class Codes: G01K 13/00 : Thermometers specially adapted for specific purposes
• CPC Class Codes: G01K 2201/00 : Application of thermometers in air-conditioning systems
• CPC Class Codes: G01N 15/0826 : and measuring fluid flow rate, i.e. permeation rate or pressure change
• CPC Class Codes: G01N 2015/084 : Testing filters
• CPC Class Codes: G01N 2015/0846 : by use of radiation, e.g. transmitted or reflected light
• CPC Class Codes: G05B 15/02 : electric
• CPC Class Codes: G05D 23/1917 : using digital means
• CPC Class Codes: G05D 23/1928 : sensing the temperature of one space
• CPC Class Codes: G05D 23/1932 : to control the temperature of a plurality of spaces
• CPC Class Codes: Y10S 116/25 : Air filter condition indicator
• CPC Class Codes: Y10S 116/42 : Oil filter
• CPC Class Codes: Y10S 55/34 : Indicator and controllers

Abstract

A real-time monitoring system that monitors various aspects of the operation of a refrigerant-cycle system is described. In one embodiment, the system includes a processor that measures power provided to the refrigerant-cycle system and that gathers data from one or more sensors and uses the sensor data to calculate a figure of merit related to the efficiency of the system. In one embodiment, the sensors include one or more of the following sensors: a suction line temperature sensor, a suction line pressure sensor, a suction line flow sensor, a hot gas line temperature sensor, a hot gas line pressure sensor, a hot gas line flow sensor, a liquid line temperature sensor, a liquid line pressure sensor, a liquid line flow sensor. In one embodiment, the sensors include one or more of an evaporator air temperature input sensor, an evaporator air temperature output sensor, an evaporator air flow sensor, an evaporator air humidity sensor, and a differential pressure sensor. In one embodiment, the sensors include one or more of a condenser air temperature input sensor, a condenser air temperature output sensor, and a condenser air flow sensor, an evaporator air humidity sensor. In one embodiment, the sensors include one or more of an ambient air sensor and an ambient humidity sensor.

Claims

1. A monitoring system for monitoring the operation of a refrigerant-cycle system, comprising:

a plurality of condenser unit sensors configured to measure operating characteristics of a condenser unit, said plurality of condenser unit sensors comprising a sensor to sense when a compressor in said condenser unit is drawing electrical power, said plurality of condenser unit sensors further comprising at least a first temperature sensor, said condenser unit comprising a condenser and a compressor;

one or more evaporator unit sensors configured to measure one or more operating characteristics of an evaporator unit, said one or more evaporator unit sensors comprising at least a second temperature sensor configured to measure an output air temperature of said evaporator, said evaporator unit comprising an evaporator and an air-handler fan;

one or more ambient sensors configured to measure one or more ambient conditions;

at least one current sensor configured to measure current provided to a motor connected to a fan; and

a processing system configured to calculate an efficiency of said refrigerant-cycle system using at least a portion of the data from each of said plurality of condenser unit sensors, at least a portion of the data from each of said one or more evaporator unit sensors, at least a portion of the data from said one or more ambient sensors, and at least a portion of the data from the at least one current sensor.

2. The monitoring system of claim 1, wherein said processing system is configured to calculate energy usage.

3. The monitoring system of claim 1, wherein said processing system is configured to calculate energy costs due to inefficient operation of said refrigerant-cycle system.

4. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to low airflow.

5. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to excessive load.

6. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to refrigerant undercharge.

7. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to refrigerant overcharge.

8. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to liquid line restriction.

9. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to suction line restriction.

10. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to hot gas line restriction.

11. The monitoring system of claim 1, wherein said processing system is configured to identify performance problems due to inefficient compressor operation.

12. The monitoring system of claim 1, wherein said processing system is configured to provide data for plots of energy usage and costs.

13. The monitoring system of claim 1, wherein said processing system is configured to provide data related to operation of said refrigerant-cycle system to a remote monitoring center.

14. The monitoring system of claim 1, wherein said processing system is configured to provide data related to operation of said refrigerant-cycle system to a remote monitoring center using power line networking.

15. The monitoring system of claim 1, wherein said processing system is configured to provide data related to operation of said refrigerant-cycle system to a remote monitoring center using broadband over power line networking.

16. The monitoring system of claim 1, further comprising an electronically-controlled metering device to allow control of refrigerant into an evaporator in an energy-efficient matter.

17. The monitoring system of claim 1, wherein said monitoring system is configured with data regarding a maximum expected efficiency for the refrigerant-cycle system.

18. The monitoring system of claim 1, wherein said monitoring system is configured with data regarding a type of refrigerant used in the refrigerant-cycle system.

19. The monitoring system of claim 1, wherein said monitoring system is configured with data regarding the characteristics of the condenser.

20. The monitoring system of claim 1, wherein said monitoring system is configured with data regarding the characteristics of the evaporator.

21. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises a temperature sensor configured to measure a temperature of the refrigerant in a suction line.

22. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises a temperature sensor configured to measure a temperature of the refrigerant in a liquid line.

23. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises a temperature sensor configured to measure a temperature of the refrigerant in a hot gas line.

24. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises a pressure sensor configured to measure a pressure of the refrigerant in a suction line.

25. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises a pressure sensor configured to measure a pressure of the refrigerant in a liquid line.

26. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises a pressure sensor configured to measure a pressure of the refrigerant in a hot gas line.

27. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises at least one refrigerant flow sensor.

28. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises at least one refrigerant contaminant sensor.

29. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises at least one condenser fan tachometer.

30. The monitoring system of claim 1, wherein said plurality of condenser unit sensors comprises at least one temperature sensor configured to measure a temperature of air out of said condenser.

31. The monitoring system of claim 1, wherein said at least one evaporator unit sensors comprises a temperature sensor to measure a temperature of refrigerant into said evaporator.

32. The monitoring system of claim 1, wherein said at least one evaporator unit sensors comprises a temperature sensor to measure a temperature of refrigerant out of said evaporator.

33. The monitoring system of claim 1, wherein said at least one evaporator unit sensors comprises a temperature sensor to measure a temperature of air into said evaporator.

34. The monitoring system of claim 1, wherein said at least one evaporator unit sensors comprises a temperature sensor to measure a temperature of air out of said evaporator.

35. The monitoring system of claim 1, wherein said at least one evaporator unit sensors comprises at least one humidity sensor.

36. The monitoring system of claim 1, wherein said at least one evaporator unit sensors comprises at least one air flow sensor.

37. The monitoring system of claim 1, wherein said at least one evaporator unit sensors comprises at least one differential pressure sensor.